2013 LINERBOARD & MEDIUM MANUFACTURE COURSE
PRELIMINARY COURSE SCHEDULE
Subject to Change
Supplemental Overview of Linerboard Seminar
Monday, August 12
8:00 – 5:00
Overview of Corrugating
Overview of Tests & Properties
Overview of Pulp Mill Operations & Recycling
Overview of Stock Preparation
Overview of Paper Machine Operations
Day 1 Tuesday, August 13
8:00 – 8:30 Welcome, Introductions, Learning Objectives
8:30 – 12:00 The Corrugating Process (overview of equipment/operations & focus on how to improve bonding between the liner and medium)
- Double-Wall Corrugator Wet End Summary
Liner, Medium, Adhesive
- Lay-out of Equipment (Numbering/Stations)
Liner roll stand (position 3)
Preheater
Medium Splicer (position 2)
Medium roll stand (position2)
Medium pre-conditioner
Bridge Elevator Belt.
Double-face
Double-facer Liner Splicer (position 1)
Double-face Liner rollstand (position 1)
Triple pre-heater
a. Function
b. Wrap-arms
Glue Unit
a. Function b. Additional preheaters
- Corrugator Terms and Variables
Web
Single Face Single Wall
Double Wall
Triple Wall
Paper Grades
Basis Weight
Standard weights
Construction of Box
Box Blank
Paper Characteristics
Liners (Two sides), Medium
Moisture
Basis Weight
- Optimizing Bonding in the Corrugator
Application is the first stage of the adhesive bonding process. The applications differ slightly for the single-face liner and the double-face liner. The application stage relates to the amount of starch applied to the flute tips.
b. Wetting and Penetration step
Critical to the strength of the bond. Several variables can affect this phase. (more on this topic in Process Control section). Both medium and liner papers must have the starch penetrate their surface.
c. Gelatinization & Green Bond steps
This Green Bond holds paper together, but still contains a significant amount of moisture.
d. Evaporative Bond - Wetting/Penetration (DF) steps Controlling factors: temperature, pressure, speed
Evaporative bond mechanisms during the first 2-3 seconds
e. Gelling & Green Bond for Pressure Bond (DF) steps
Mechanisms during bond formation
f. Drying/Fully Curing step
Final Evaporative bond formation in the final 1-2 seconds.
12:00 – 1:00 LUNCH
1:00 – 5:00 Linerboard & Medium Performance Properties & Tests
(focus is on liner and medium performance properties and tests; and how the liner & medium properties affect corrugator runnability)
What happens to the Linerboard & Medium in the Corrugating Process
Sheet Structure & why it’s important, MD/CD Fiber Orientation, Formation
Properties & Tests, what they are telling us, and what contributes to their values
Stiffness, Ring Crush, Mullen, Concora
Edgewise Compression Test, STFI
Tensile, Modulus, Stretch
Liquid Absorption, Porosity, Adhesion
Sizing tests, Cobb, Water drop, etc.
Moisture & Humidity Effects on Performance Properties
Causes of Curl, Warp, & Wash Boarding
Viscoelastic Creep Failure of Boxes
Printability & Smoothness
CASE STUDIES - How Properties affect Runnability on the Corrugator
Others, as per pre-course survey of participants
5:30 Adjournment
Day 2
Wednesday, August 14, 2013
8:00 – 10:00
Improving Performance I : Fiber Raw Materials, Pulp Properties
• Fiber Properties & Effects on Sheet Structure
• Pulping Processes for Liner & Medium
10:00 – 11:00
Improving Performance II: Recycling
• Recycled Fiber Quality
• Stickies
11:00 – 12:00
Improving Performance III: Stock Prep Refining
• Refining mechanism
• Effects on sheet and properties
• Refining Measurements and Variables
• Improving Refining for Linerboard & Medium
12:00 – 1:00 LUNCH
1:00 – 4:00
Improving Performance III: Chemical Additives
pH control
• Dry & Wet Strength
• Sizing
• Fillers
• Formation Aids, Retention
• Wet End Chemistry Improvement
4:00 – 5:00
Case Studies
• Chemical Additives & Effects
• Refining
5:00 Adjournment
Day 3
Thursday, August 15, 2013
8:00 - 10:00
Improving Performance IV: Paper Machine Wet End Operations
• Approach system
• Headbox operations
Pressure/Hydraulic
Importance of and Variables affecting Formation
Microturbulence Strategies
Jet/Wire & MD/CD Orientation
Structure CD, MD, Z Variations
Headbox Crossflows & BW profile control
• Sheet forming
Dewatering
Formation Improvement & Microturbulence
Top Sheet Forming
Twin Wire Gap Formers, Hybrid Formers
10:00 – 11:00
TSI/TSO Analysis & Case Studies
11:00 – 12:00
Improving Performance V: Pressing, Drying, Calendering
• Pressing Mechanism of Water Removal; Effect on Sheet Properties Shoe Pressing & other developments
• Effects of Drying and Shrinkage & Moisture profile on Liner & Medium sheet & properties
• Types of calenders & variables affecting calendering
• Calender box surface treatments
• Winding
12:00 – 1:00 LUNCH
1:00 – 2:30
Improving Performance VI : Machine Clothing
• Forming Fabrics
• Wet Press Fabrics
• Drying Fabrics
2:30 -3:30
Paper Machine Operations VI : Size Press & Other Surface Treatments
• Variables affecting pick up
• Developments in Size Press
• Surface Treatment Chemicals & Coatings to Improve Linerboard
3:30- 4:30
Printability, Developments in Printing & Demands on Linerboard & Medium
Preprint and Post Print
Linerboard surface requirements
Flexo process improvements
Photopolymer plates and packing materials
High definition halftones
Staccato screening
More colors
Digital printing of corrugated
High speed pigmented ink jet
Surface quality requirements
4:30 Wrap up, evaluations and adjournment